Chain out of plane bending fatigue

1. Girassol failures and OPB mechanism

2. Phase 1: validation
 OPB stress measurement
 Analytical
3. Phase 2: Reduced scale chain OPB fatigue tests
4. Conclusions
5. JIP proposal
 1 - Story of Girassol failure events
State of the art design
 Girassol chains designed according to conventional fatigue
assessment using API RP2SK T-N curves
 API fatigue life >60 years (3 x design life)
According to industry best practice in 2001 Girassol mooring

should not have failed!
Girassol events
 Several chains broken in ~ 8 months
 Failure on link 5
 Bushing friction torque higher than interlink friction torque
 Chain must bend before bushing rotates

=>New source of fatigue : Out

of Plane Bending
SBM developed a
Failed link
methodology to assess
performance of chains under
Chainhawse
this new fatigue mechanism
1 - Story of Girassol failure events
 1 - OPB Failure mechanism
 Tension fatigue is due to
ΔT cyclic range of tension
variations loading the
chain.

 OPB fatigue is due to

range of interlink rotation
under a certain tension.

T  Occurs predominantly in
the first link after a link that
is constrained against free
rotational movement.

Δb  Failure can be fast.

 Link Constraint provided by

Chainhawse or Fairlead.
Mechanism aggravated by high pretensions and is
generating critical cyclic stress loading
1 - Failure mechanism
Crack propagation initiated
at hot spot stress in bending

Crack initiation due to

corrosion pitting
Area of max stress
in Out of Plane
Rupture in 235 days Bending

MOPB

Crack propagation
1 - Interlinks locking modes
 Bending stress:
r0
r
αint s OPB = M OPB �i
ri I
αi  Rolling
  ri 
F M OPB 
= ri * T * sin  b   int *   
N 
β
T   r0  ri 

 Sticking

M OPB = k * T a *  2ri  *  int

1

 Sliding:
m friction �
M OPB = ri � T
1 - Interlinks contact area
Flat contact area generated by the proof load test (> 66% MBL)

This indentation area may encourage “sticking mode” / “rolling

mode”

Finite Element plastic analysis at proof load

Indentation area
Girassol recovered link
2 – 1st test phase: OPB s measurement
SBM laboratory tests :
measurement of bending
stresses in chains

Chain size (mm): 81, 107, 124, 146

Tension : 20 t  94 t
2 - Experiments & analysis
Bending stress variation against interlink angle

Test campaign to measure OPB stress in “sticking” locking mode

• Determine the influence of:
- Tension
- Diameter
- Interlink angle
• Derive an empirical law
s OPB = f (T , d ,  )
 2a– Quarter-Link Model
OPB Link:
Link X-Section rotates
with RP node, T/2 loading
distributed via kinematic
coupling. Cases:
2  94 ton tensile loading
with zero friction
 94 ton tensile loading
with μfriction=0.25, 0.5
3 1
T/2  60% CBL (878 ton)
OPB Link:
Applied loading rotates
with μfriction=0.5
with link rotation
Surface Contact
 94 ton tensile loading
And friction wth μfriction=0.1
 94 ton tensile load
with OPB link forced
Fixed Link:
Symmetric B.C. 2-3 plane: U1 = 0.0
sliding μfriction=0.3
3-direction: ? U3 = 0.0 (distributed
coupling)

2 FEA Details:
3
 Elastic material with contact
T/2 and friction
1  +/- 2° amplitude

Fixed Link and OPB Link:

Symmetric B.C. 1-3 plane: U2 = 0.0
OPB Link:
Constraint to enforce friction sliding
(3-direction): ? U3 = 0.0 (distributed
coupling)
2a– Rolling
2a– Sliding
2a– Sticking-Sliding
2a– Sticking-Sliding vs. Rolling
Experiment and FEA
124 mm Chain links
60

50 Sticking-Sliding
Stress amplitude (MPa)

40 94 ton, test #30

85 ton, test #30

60 ton, test #30

30
80 ton, test #30
65 ton, test #30

20 Sticking-Sliding

Roilling

10 Rolling

0
0 0.2 0.4 0.6 0.8 1 1.2 1.4

Interlink angle (degrees)

2a– 3-Link Model

Experimental setup for 124mm links

2a– 3-Link Model

Ramberg-Osgood Stress-Strain Curve

1200

1000

Stress (MPa)
800
Engineering
600 True

Yield 580.0 MPa

400 Ultimate 860.0 MPa
eps ult = 12.0%
200 alpha = 0.71
n = 10.3
0
0% 5% 10% 15%

Strain
2a– 3-Link Model
2a– 3-Link Model Nonlinear vs. Elastic
94 ton tensile loading, rig shoe 150 mm, 94 ton tensile loading, rig shoe 150 mm,
μfriction=0.3, elastic μfriction=0.3, von-Mises
Incremental S11
f = 0.3, d = 150mm, plasticity, T= 94 ton
30

20

10

S11 in OPB link (MPa)

0

-10

-20

-30

-40
0 1 2 3 4 5
Interlink Angle (degrees)

Experiment and FEA

124 mm Chain links
60

94 ton, test #30

50
85 ton, test #30

Stress amplitude (MPa)

60 ton, test #30
40 80 ton, test #30

65 ton, test #30

30 FEA 3-link, 94 ton , nonlinear

20

10

0
0 0.2 0.4 0.6 0.8 1 1.2 1.4

Interlink angle (degrees)

2a– 3-Link Model with Proof Loading
 2a– 3-Link Model with Proof Loading

60% MBL preload, 94 ton tensile loading, rig

shoe 150 mm, μfriction=0.3, von-Mises

Incremental S11
Experiment and FEA
f = 0.3, d = 150mm, plasticity, T=878 ton (60% CBL) 94 ton
124 mm Chain links
50 60

40
50

Stress amplitude (MPa)

30
20
S11 in OPB link (MPa)

40
10
94 ton, test #30
0 30 85 ton, test #30

-10 60 ton, test #30

20 80 ton, test #30
-20
65 ton, test #30
-30 10 FEA 3-link, 60%CBL to 94 ton, f=0.3

-40
-50 0
0 0.2 0.4 0.6 0.8 1 1.2 1.4
0 1 2 3 4 5 6
Interlink Angle (degrees) Interlink angle (degrees)
2a– Link Intimacy

Plastic Strains and Interlink Contact Intimacy

for no-Preload vs. 80% CBL Preload

94 ton Load with no Preload 94 ton Load after 80% MBL

2a– Effect of Proof Load and Operating Tension

Experiment and FEA

124 mm Chain links
60

50
Stress amplitude (MPa)

40
94 ton, test #30

85 ton, test #30

30
60 ton, test #30

80 ton, test #30

20
65 ton, test #30

FEA 3-link, 60%CBL to 94 ton, f=0.3

10 FEA 3-link, 80%CBL to 94 ton, f=0.3

FEA 3-link, 40%CBL to 94 ton, f=0.3

0 FEA 3-link, 80%CBL to 60 ton, f=0.3

0 0.2 0.4 0.6 0.8 1 1.2 1.4

Interlink angle (degrees)

2 - Conclusion from the 1st test campaign
Better understanding of the OPB phenomena

Empirical relationship to predict OPB stress

Redesigned Chain connection

Predictions have been done on other mooring chain with surprising

results. Although traditionally neglected, OPB fatigue damage can be
significant.

Further tests are still undergoing to determine more accurately the

OPB stress relationship.
3 – 2d test campaign: fatigue testing
 Test program:
• Monitoring of 40 mm chain links in 2 rescaled hawse
(Girassol and Kuito)
• Fatigue test with both hawses (in salt water)
 Aim:
• Investigate the interlink angle distribution in both hawses:
influence of the chainhawse design
• Validation of the stress relationship for smaller link Ø.
• Obtain fatigue endurance data for OBP stresses
3 – Phase 2: fatigue test campaign
 2 Chainhawse type tested

 Fatigue test results

• Girassol design:
Pretension Lab results
50t pitch A 139500
50t + preload 94t Pitch A 102700
35t Pitch A 609500

• Kuito design:
- Pitch A: 1 million of cycles: no failure
- Pitch B: 1.3 million of cycles : no failure
3 - Girassol results
 Angle variation function of the
stroke

 Propagation : p1 ≈ 80% for

T=35t
 Angle transmit by L4 larger
than the induced hawse
angle

 Stress level at 35 t:
 Total hawse angle variation:
tot ≈ 6.44°

 Interlink angle variation on

L5: int ≈ 4.9°

 Bending stress range on L5:

smax≈ 380 MPa

Note: s,NT ≈ 140 MPa

3 - Kuito results
 Angle variation function of
the stroke
 Propagation : p1 ≈ 34%
for T=35t

 Stress level at 35 t:
 Total hawse angle
variation: tot ≈ 2.70°

 L2 Interlink angle
variation: int ≈ 0.92°

 L2 Mean stress range:

smax≈ 280 MPa for
T=35t
3 - Stress function of interlink angle
 Kuito results
 Pitch A, Pitch B in air
and in seawater :
quite good
consistency

 Stress relationship
 Kuito chainhawse :
slope at origin
matches old
relationship, then
higher stresses 0.7
Summary of OPB tests results and determination of reduced curve
parameters
Average curves 81 mm 124 mm
0.6
Kuito reduced stress
 Girassol chainhawse: 0.5
Kuito Pitch B in water reduced stress
Girassol reduced stress

stress level in Rolling reduced stresses for r0=30 mm

Rolling reduced stresses for r0=22.8 mm
between theoretical 0.4 Poly. (Average curves 81 mm 124 mm)

rolling stress and 0.3

locking stress
0.2

0.1

Interlink angle (dg)

0
0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0
3 - Fatigue performance and S-N curve
 Stresses
 Maximum bending
stresses are derived from
measured stresses on
link by multiplying by a
SCF (1.08)
 S-N curve Measured
 Straight chainhawse stress
results: non failure
 For high stress range,
DNV in air mean curve
gave a nice prediction 2.8 S-N curve

 Corrosion pitting at the

end of the test may not 2.6
be representative from log ( s)

long term offshore 2.4

corrosion
2.2
 For lower stress ranges, DNV RPC203 B1 free corrosion mean S-N curve

the predictions may be 2 Curve chainhawse maximum stresses (failures points)

DNV RPC203 B1 with CP mean S-N curve

too conservative Straight chainhawse max stresses in water (non failures)

DNV RPC203 B1 in air mean S-N curve
log (N)
BS7608 B in air mean S-N curve
1.8
4 4.5 5 5.5 6 6.5 7 7.5 8
4 - Conclusions
 Stress relationship
 The chainhawse geometry can affect the mode of interlink interaction
- The curved chainhawse tend to concentrate the chain rotation to a
single interlink angle rotation
- The straight chainhawse tend to evenly spread out the chain
rotation to several interlink angles
- The curved chainhawse exhibit lower stress as a function of int
but int a lot larger  higher stresses than on the straight
chainhawse
 Previously obtained stress relationship function of int
• Matches initial slope for the straight chainhawse but then tend to
underestimate the stresses
• Overestimate the stresses for the curved chainhawse (rolling?)
 S-N curve
 Standard S-N curve seem to give conservative predictions
 The trend seems to show a lower S-N curve slope (higher m value)
compared to standard S-N curve
 A link in bending experiences significant shear at the OPB peak stress
 need of specific S-N curve for similar loading conditions
5 - JIP proposal
 FURTHER NEEDS:
 Need OPB Stresses for higher tension levels (% MBL).
 More endurance data for chain links subjected to OPB.
 DELIVERABLES:
 Improved Chain OPB stress relationships.
 S-N curves to be used for OPB fatigue calculation.
 RP
 SCOPE OF WORK :
 OPB stress measurements based on chain tests in the SBM
laboratory (4 different chain size for 4 higher levels of tension).
 Use FEA, in line with the work done by Chevron to calibrate the
interlink stiffness and sliding threshold model by benchmarking
tests results.
 Develop a specific test rig for fatigue testing of chain-links in OPB.
 S-N curve determination.
 Develop RP for OPB fatigue prediction.
5 - JIP proposal
 JIP value
• Improve the safety of deepwater mooring systems by providing a
more accurate assessment method for OPB fatigue.
• Added value: contribution of previous SBM and Chevron work (See
2005 OTC & 2006 OMAE papers)
 Budget
Hrs Cost$US
SBM chain test refurbishment for other chain size and higher loads 50000
Chain purchasing (4 different sizes) 20000
Tests of different chains (4) for (4) different tension levels 800 80000
Calibrate FEA interlink stiffness model / tests results 300 30000
Design a chain fatigue test rig 500 50000
Construct fatigue test rig 150000
Fatigue test about 15 samples for S-N curve determination 1000 100000
Prepare design methodology for OPB fatigue determination for a 200 20000
Recommended Practice.
-  Total Cost 500000
JIP Contribution 250000
SBM Contribution 250000
 Questions?

Please Contact SBM Monaco

Lucile Rampi
Lucile.rampi@singlebuoy.com
00-33-92-05-86-24